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Pub. No. EE14E-11162
SERVICE MANUAL REPAIR SERVICE& MAINTENANCE
VRZ
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The following marks are used in this service manual to facilitate correct VRZ maintenance.
Advice Procedures that must be performed to enable the best possible VRZmaintenance.
Note Information assisting in the best possible VRZ maintenance.
MEANINGS OF MARKS
WARNINGS
The following definitions and warning signs are used in this service manual.These are extremely important to safe operation.Important points are described to prevent bodily injury and property damage.They must be fully understood before beginning VRZ maintenance.
CAUTION!! Improper maintenance can result in injury and property damage.CAUTION
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FOREWORDThe contents of the manual, includingillustrations, drawings and specifications werethe latest available at the time of printing.
The right is reserved to make changes inspecifications and procedures at any timewithout notice.
BOSCH K.K.Sales Automotive Aftermarket Division
This service manual describes the disassembly,inspection, reassembly and adjustment of theVRZ (radial plunger system position-control
distributor type fuel injection pump).Refer to the separate service manuals listedbelow to facilitate VRZ type injection pumpmaintenance.This manual is intended for use by vehiclemaintenance technicians or persons with anadequate knowledge of injection pumps.
Service manual Publication number
VRZ Construction and Operation EE14E-11150
INJECTION PUMP TEST BENCH 10NP & 20 NP, Operation EC18E-11081
CONTINUOUS MEASURING DEVICE ZCM & ZCD, Operation EC18E-11091
CONTROLLER ASSEMBLY MC-02, FOR VRZ & COVEC-F EC14E-11022
WITH EEP-ROM, Operation
MC-02 TESTER SOFTWARE, ADJUSTMENT AND INSPECTION ED14E-11011
DATA, FOR VRZ AND COVEC-F WITH EEP-ROM, Installation
ECU ASSEMBLY, ADJUSTMENT AND INSPECTION DATA, ED14E-11021FOR VRZ AND COVEC-F WITH EEP-ROM, Installation
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SERVICE PRECAUTIONS
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[1] Carrying the injection pump Never knock or drop the injection pump
when carrying it.
When carrying the injection pump, hold thepump by the bottom of the pump body.
P-VRZR- 320
P-VRZR- 321
P-VRZR- 322
P-VRZR- 323
Pump body
GE actuator
GE actuator
Wire harness
Harness connectors
GE actuator
Wire harness
Injection pump
Injection pump
Never hold the pump by the GE actuator orthe harnesses.Holding the pump by these components mayresult in damage or injury.
CAUTION
[2] Disassembly and reassembly Only the mechanical components of the
injection pump body can be disassembledand reassembled.
AdviceDo not disassemble the GE actuator otherthan directed in this manual. The GE actuator consists of electrical
components. Do not damage them.
When cleaning the injection pump, do notclean the GE actuator, the harnesses, or theharness connectors using fuel oil. Use onlyclean waste cloth.
Injection pump
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SPECIAL TOOLS
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20 21
2233
34
24
26
8
11
12
28
23
14
15
25
16
37
36
17
35
18
19
31
32
30
10
9
5
3, 4
1
2
13
27
29
6
7
1. DISASSEMBLY, INSPECTION AND REASSEMBLY TOOLS[1] Tool use locations
P-VRZR- 324
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SPECIAL TOOLS
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Keyno
RBAJ part no Bosch part no Part name Qty Remarks
30
31
32
33
34
35
36
37
157915-9700
157928-4800
157917-4920
157977-8000
026512-1640
157971-0500
157924-8520
157928-4400
9 681 610 686
9 442 612 302
9 681 610 711
9 681 610 829
9 421 617 041
9 443 613 408
9 681 611 028
9 442 612 371
Socket
Plate
Wrench
Adapter
Gasket
Clip
Base
Pliers
1
1
1
1
3
1
1
1
For removing and installing pump support
bracket (T50)
For temporarily holding feed pump
For turning auxiliary gear
For inlet piping
For inlet piping
For fixing plunger
Stand for installing drive gear
For removing and installing drive gear snapring
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SPECIAL TOOLS
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10. 157928-4120(9 442 612 299)Extractor
11. 157829-3520(9 681 610 171)Measuring device
12. 157845-8900(9 681 610 626)Adapter
13. 105782-4530(9 680 610 094)Measuring device
14. 157917-4620(9 681 610 710)Wrench
15. 157848-2300(9 681 611 027)Oil seal guide
16. 157926-2421(9 681 610 773)Extractor
17. 157927-4500(9 443 613 008)Puller
18. 157928-5820(9 443 613 397)Hook
46
25 75
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SPECIAL TOOLS
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19. 157928-3120(9 442 612 297)Clip
20. 157928-3620(9 442 612 298)Holder
21. 157928-4200(9 442 612 369)Guide
22. 157928-4500(9 442 612 300)Set screw
23. 157928-4700(9 442 612 301)Spacer
24. 105782-4540(9 680 610 095)Measuring device
25. 157847-0820(9 442 612 370)Coupling
26. 157915-9820(9 681 610 687)Holder
27. 157915-9201(9 681 610 684)Bit
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SPECIAL TOOLS
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1. 105796-0000(1 688 010 129)Fixing stand
2. 157808-4720(9 442 612 278)Injection pipe
3. 157641-6820(9 443 612 974)Joint assembly
4. 157811-9020(9 681 610 453)Flange
5. 157829-0820(9 681 610 336)Adjusting device
6. 157971-1020(9 443 613 442)Piping assembly
8. 105793-0020(9 681 610 418)Adjusting device
9 . 157845-9520(9 681 610 630)Pipe assembly
7. 105781-0890(9 680 610 087)Stand
200
11
M10X1.0
M12X1.5
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SPECIAL TOOLS
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[3] Adjustment controller assembly breakdown:Key no. 1: 105782-8360 (9 680 610 209)Note:The numbers in brackets below are Bosch part numbers.
Adjustment controller assembly part table (for VRZ)
1:105782-8360(9 680 610 209)
1-1: 157966-4020(9 443 613 446)
1-2: 157966-3720
(9 443 613 456)
1-3: 157966-3820(9 443 613 457)
1-4: 157966-3920
(9 443 613 458)
1-1-1: 157966-4120 (9 443 613 447)
1-1-9: 157966-5100 (9 443 613 455)
1-1-8: 157966-5020 (9 443 613 454)
1-1-7: 157966-4920 (9 443 613 453)
1-1-6: 157966-4820 (9 443 613 452)
1-1-5: 157966-4720 (9 443 613 451)
1-1-4: 157966-4620 (9 443 613 450)1-1-3: 157966-4520 (9 443 613 449)
1-1-2: 157966-4420 (9 443 613 448)
Keyno
RBAJ part no Bosch part no Part nameQty
Remarks
1-1 157966-4020 9 443 613 446 CONTROLLER ASSY 1
1-1-1 157966-4120 9 443 613 447 Controller unit 1 Checker assy
1-1-2 157966-4420 9 443 613 448 Wire harness 1 Power supply (Japan, USA)
1-1-3 157966-4520 9 443 613 449 Wire harness 1 Power supply (EC)
1-1-4 157966-4620 9 443 613 450 Wire harness 1 PC: COM1 ~ MC-02
1-1-5 157966-4720 9 443 613 451 Wire harness 1 PC: COM2 ~ MC-021-1-6 157966-4820 9 443 613 452 Wire harness 1 FCV GND harness
1-1-7 157966-4920 9 443 613 453 Main harness 1 Controller-Pump GE
1-1-8 157966-5020 9 443 613 454 Main harness 1 Controller-Pump ROM
1-1-9 157966-5100 9 443 613 455 CD-ROM 1 Software (Overseas Ver.) & (Calibration data)& Manual
1-3 157966-3820 9 443 613 457 ECU assembly 1 For Mitsubishi 4M41 engines
Note:Key number 1 (RBAJ part no.105782-8360, Bosch part no. 9 680 610 209) enables adjustment ofboth VRZ and COVEC-F pumps.With the VRZ, however, only key numbers 1-1 (RBAJ part no. 157966-4020, Bosch part no. 9 443613 446) and 1-3 (RBAJ part no. 157966-3820, Bosch part no. 9 443 613 457) are necessary.
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SPECIAL TOOLS
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1-1 157966-4020(9 443 613 446)CONTROLLER ASSY
1-1-1 157966-4120(9 443 613 447)
Controller unit
1-1-4 157966-4620(9 443 613 450)Wire harness
1-1-2 157966-4420(9 443 613 448)Wire harness
1-1-5 157966-4720(9 443 613 451)Wire harness
1-1-6 157966-4820(9 443 613 452)Wire harness
1-1-7 157966-4920(9 443 613 453)Main harness
1-1-8 157966-5020(9 443 613 454)Main harness
1-1-9 157966-5100(9 443 613 455)CD-ROM
1-1-3 157966-4520(9 443 613 449)Wire harness
20002000
2000
1000
2990
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DISASSEMBLY
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161
922
100
101
160
102
878S
925 923
920
912914
90550
22
3537
36
33
65
34
50
11
83
80/7
45
38
931 930
46
3132
3530
62
53
61
50
54 60
51
2018
9
8080/8
1
4243
4140
82
66
108
76
5
15
810S 856S2726
2
910911
3
56
205
17
25
16
55
948 949
110
949
50
111
112
50
130
150/8152
150
153
956
955
151
121
120
122
1. PREPARATION Clean the outside of the injection pump
before disassembly, removing all grease anddirt. Drain the fuel oil from the pump.
Keep the work bench and workshop cleanand tidy.
Before beginning disassembly, recordperformance data for later reference tofacilitate the diagnosis of malfunctions anddefects, if any, in the pump.
2. EXPLODED VIEW
P-VRZR- 326
Lay out the disassembled parts neatly andsequentially on the work bench, labellingthem if necessary, to facilitate laterreassembly.
Prepare a container of clean fuel oil forplungers, delivery valves and other precisionparts.
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DISASSEMBLY
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3. ENGINE DRIVE GEAR REMOVAL(1) Fix the injection pump bracket in a vise.
(2) Install wrench B so that it can turn the twogears (ie, the main gear and the sub-gear)clockwise.
(3) Turn the main gear and the sub-gear usingwrench A until they are aligned. Then, inserta bolt through the two gears and tighten itus ing a torque wrench. (T ightentemporarily.)
(4) Remove wrenches A and B and the torquewrench from the drive gear.
(5) Install wrench B so that the main gear andthe sub-gear are in the center of wrench B.
(6) Remove the bolt from the drive gear.(7) Align the main gear and the sub-gear using
wrench A, then install the bolt and tightento the specified torque.
Specified torque: 9 ~ 13 Nm{0.9 ~ 1.3 kgfm}
Note:
The drive gear is divided into the main gear andthe sub-gear.Wrench B is used to prevent drive gear rotation.Wrench A is used to align the main gear andthe sub-gear.
Tool name Part no Remarks
Wrench A 157917-4920
Wrench B 157917-4620
P-VRZR- 300
P-VRZR- 301
Injection pump body
Drive gear
Wrench A
Wrench B
Bolt (M6x1)
P-VRZR- 318
Drive gear
Wrench A
Wrench B
Bolt (M6x1)
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DISASSEMBLY
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(8) Remove wrench A.
(9) Remove the roundnut (SW21) fixing thedrive gear.
(10) Assemble puller A in the gap between the
drive gear and the bracket and loosely fixthe bolts.
(11) Assemble puller B to the drive shaft andpuller A.
Tool name Part no Remarks
Puller 157927-4500 Parts A and B
P-VRZR- 302
P-VRZR- 303
P-VRZR- 305
P-VRZR- 304
Sub-gear
Socket wrench
Bolt
Puller A
Drive shaft
Puller B
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DISASSEMBLY
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(12) Tighten the puller bolt to remove the drivegear.
AdviceHold the puller so that it does not drop whenthe gear is removed from the drive shaft.
(13) Remove the drive shaft key.
(14) Remove the nuts (at three locations).
(15) Remove the bracket from the pumphousing and then remove the O-ring.
P-VRZR- 306
P-VRZR- 307
P-VRZR- 319
Drive gear
Bolt
Key
Nuts (3)
Bracket
O-ring
Drive shaft
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DISASSEMBLY
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[2] Magnet valve removal(1) Remove the magnet valve harness grommet
and then remove the harness nut.(2) Remove the magnet valve and the filter.AdviceDo not lose the armature spring.
[3] GE actuator removal(1) Remove the GE actuators torx bolts and
spring washers.
(2) Remove the GE actuator.
AdviceDo not damage the ball pin (refer to the GEactuator on page 35).
Tool name Part no Remarks
Holder 157915-9820
Bit 157915-9600 T30
[4] Regulating valve removalAssemble the socket wrench to theregulating valve and then remove theregulating valve.
Tool name Part no Remarks
Socket wrench 157913-7000
AdviceDo not remove the GE cover.
P-VRZR- 020
P-VRZR- 021
P-VRZR- 023
P-VRZR- 022
Magnet valve
Grommet Nut
GE actuator Torx bolts (6)
Spring washers (6)
GE coverHolder
Bit
GE actuator
S o c k e t
wrenchRegulating valve
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DISASSEMBLY
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(3) Remove the TPS, the adjusting shim, thetimer spring, the core rod and the TPSstandard point shim.
AdviceLabel the TPS standard point shim and thetimer stroke adjusting shim to avoidmistaking them at reassembly.
P-VRZR- 027
TPS
Adjusting shim
TPS standard point shim Core rod
(2) Remove the TPS bolts.
P-VRZR- 026
TPS bolts (2)
TPS
Timer spring
(4) Remove the timer cover and the O-rings
(large and small).
P-VRZR- 028
Tool name Part no Remarks
Holder 157915-9820
Bit 157915-9600 T30
O-ring (small)
Timer cover
O-ring (large)
Bit Holder
Torx bolts (2)
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DISASSEMBLY
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Tool name Part no Remarks
Socket wrench 157914-3600
P-VRZR- 029
[7] CPV (constant pressure valve)holder and plug removal
(1) Loosen the CPV holders.
(2) Remove the CPV holders and the gaskets.AdviceLine up the removed CPV holders in orderto match the positions (A, B, C, D) on thedistributor head from where they wereremoved.
P-VRZR- 030
(3) Remove the plug using a hexagon wrench
(SW14mm).
P-VRZR- 031
Socket wrench
Gaskets (4)
CPV holders (4)
Plug
Hexagon wrench
Distributor head
CPV holders (4)
(4) Remove the snapring and shim from therotor shaft.
Note:The shim is easier to remove after removing thedistributor head assembly.
P-VRZR- 032
Shim
Snapring
Distributor head
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DISASSEMBLY
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(2) Remove the rotor shaft assembly andremove the rollers and roller shoes from therotor shaft.
Advice Do not drop the rollers or the roller shoes.
Do not change the roller and roller shoecombinations.
(3) Assemble the clip to prevent the plungerfrom dropping out of the rotor shaftassembly.
P-VRZR- 036
[11] Drive shaft removalRemove the drive shaft, the washer and theseal ring.
P-VRZR- 038
[10] Snapring removalInsert the hooks pin into the snaprings holeand tighten the butterfly nut to pull out thesnapring.
P-VRZR- 037
Tool name Part no Remarks
Hook 157928-5820
Rotor shaft assembly
Spring
Roller shoes
Rollers
Snapring
Hook
Drive shaft
Seal ring
Tool name Part no Remarks
Clip 157971-0500
Washer
Pin
Clip
AdviceDo not disassemble the plunger from the
rotor shaft.
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COMPONENT INSPECTION
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[7] Rotor shaft assembly(1) Replace the distributor head assembly if any
of the rotor shaft assemblys sliding partsare peeling, gnawed or scorched.
(2) Replace the washer with a new one if it isworn.
P-VRZR- 056
P-VRZR- 057
P-VRZR- 058
Timer slider
Cam ring
Rotor shaft assembly
Drive shaft assembly
(6) Replace the drive shaft assembly if there isany play between the rotor shafts ball pinand the drive shaft.
[8] Cam ring(1) Replace the cam ring if the cam ring pin is
worn.(2) Replace the cam ring if there is any play
between the cam ring pin and the timerslider.
Rotor shaft
(3) Replace the cam ring if the cam rings camprofile is peeling or scorched.
P-VRZR- 059
Radial plungers
Rollers
Roller shoes
Cam ring
Ball pin
Pin
Washer
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COMPONENT INSPECTION
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[11] CPV (constant pressure valve)holder
Replace the CPV holder if the CPV holderseat is scratched.
P-VRZR- 064
P-VRZR- 065
P-VRZR- 066
CPV holder
Control sleeve
GE actuators ball pin
(5) Assemble the GE actuators ball pin to thecontrol sleeve groove. If there is any play,replace the distributor head assembly.
[12] Plug and rotor shaft spring(1) Replace the rotor shaft spring if it is rusted
or damaged.(2) Replace the plug with a new one if it is burred
or the thread is damaged.AdviceAlways replace the O-ring assembled to theplug with a new one.
[13] Regulating valveReplace the regulating valve assembly if thepiston inside the regulating valve is sticking.
Advice Always replace the O-rings with new
ones. Do not disassemble the regulating valve
unless necessary.
P-VRZR- 067
Plug Rotor shaft spring
Regulating valve
O-rings
Stopper
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COMPONENT INSPECTION
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6
5
3
2
1
12
11
10
9
8
7
4
[14] Magnet valve(1) Replace the magnet valve assembly if the
armature is scorched or cracked.(2) Replace the magnet valve assembly if the
spring is damaged or rusted.AdviceAlways replace the O-ring with a new one.(3) Check the magnet valve resistance and
replace the magnet valve assembly if theresistance is not as specified.
P-VRZR- 068
P-VRZR- 069
P-VRZR- 070
[15] GE actuator(1) Replace the GE actuator if the ball pin isworn or if the plating is damaged or peeling.
(2) Assemble the GE actuators ball pin in the
control sleeve groove and confirm that thereis no play.If there is any play between the ball pin andthe control sleeve, replace the GE actuatoror the distributor head assembly or both.
Control sleeve
GE actuator
GE actuator
GE actuator terminals (reference)
Terminal no. Name Remarks
1 FCV Black, magnet valve
2 Blank -
3 Blank -
4 CSP (OSC) Yellow
5 TCV (+) Red
6 GE (+) White
7 TF (+) Blue, fuel temperature (+)
8 CSP (MDL) Red
9 TCV (-) Black
10 GE (-) Green
11 TF (-) Grey, fuel temperature (-)12 CSP (GND) BlackP-VRZR- 312
Magnet valve
O-ring
Spring
Armature
Ball pin (4) Clean the gauze filter.
Terminalnos
Resistance( )
Ambient temperature(C)
1 - GND 8.01.2 235
Gauze filter
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COMPONENT INSPECTION
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P-VRZR- 314
[18] Np sensorsMeasure the Np sensors resistances.
Np sensors
[19] Fuel temperature sensorMeasure fue l temperature sensorresistances.See page 35 for GE actuator terminals.Reference values:
Fuel temperature (C)
(k)
3 (+)
2 (-)
1
P-VRZR- 163
Resistance
Terminalnos
Resistance( )
Fuel temperature (C)
7 - 8 2 25
(25, 2) = (fuel temperature, resistance)
Terminal nos Resistance ( ) Remarks
2 - 3 2.15k Main
2 - 3 2.15k Backup
AdviceWhen using a digital circuit tester,resistances cannot be measured unless youhold the minus probe against the No. 2terminal and the plus probe against the No.3 terminal.
(+)
(-)
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GEAR REASSEMBLY
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P-VRZR- 333
P-VRZR- 334
P-VRZR- 335
P-VRZR- 336
(7) Attach the sub-gear to the main gear. Atthis time, hook the sub-gears pin to thespring.
(8) Align the wrench with the sub-gears holesand attach it to the sub-gear.
Tool name Part no RemarksWrench 157917-4920
(9) Turn the wrench counterclockwise to align
the main gears teeth with the sub-gearsteeth.
(10) Screw in the socket head bolt (SW5) totighten the sub-gear to the main gear.
Specified torque: 9 ~ 13 Nm{0.9 ~ 1.3 kgfm}
Part namePart no
(Mitsubishi part no)Remarks
Socket head bolt149917-1500(ME204287)
SW5
CAUTION
Socket head bolts cannot be reused.
(11) Hold the snapring open using pliers andinstall it in the main gears snapring groove.
Part namePart no
(Mitsubishi part no)Remarks
Snapring 149931-1600(ME204236)
Tool name Part no Remarks
Pliers 157928-4400
Socket head bolt
Wrench
Sub-gear
PliersSnapring
Main gear
Base
Pin
Sub-gear
Spring
Sub-gear
Wrench
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REASSEMBLY
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The reassembly of the VRZ type injection pumpis basically the reverse of the disassemblyprocedure. The following describes the standardreassembly procedure.Always replace gaskets and O-rings with new
ones.1. REASSEMBLY[1] Feed pump assembly reassemblyAdvice Confirm that the blades grooves are
positioned toward the inside. Blade and rotor orientation cannot be
changed. The feed pumps liner is marked with an
R for clockwise injection pump rotation
or an L for counterclockwise injectionpump rotation. Install the liner so thatthe applicable mark can be seen whenthe liner is viewed from the head side.
Tool name Part no Remarks
Feed pump holder 157928-4320
P-VRZR- 077
P-VRZR- 078
Blade
Liner
Rotor
(2) Position the feed pump cover notch towardthe GE actuator side and insert the feedpump assembly into the pump housing untilthe feed pump is contacting the housing.
(3) Hold the feed pump holder so that it doesnot move and turn the pump housing upsidedown.
P-VRZR- 079
Cover
Feed pumpFeed pump holder
Feed pump holder
Pump housing
Stamping
Pins
Chamfer
Notch
Notch
(1) Position the feed pump assembly and the
cover on the feed pump holder. Assemblethe holder pins in the feed pump holes (2).
AdviceAlign the feed pump cover notch with thefeed pump holder chamfer.
Notch
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P-VRZR- 083
P-VRZR- 084
(10) Remove the set screw and install the othertwo torx bolts.
(11) Tighten the four torx bolts uniformly. (Oneof the four torx bolts does not screw intothe pump housing.)
Specified torque: 3.0 ~ 4.0 Nm{0.3 ~ 0.4 kgfm}
Tool name Part no Remarks
Holder 157915-9820
Bit 157915-9201 T15
For feed pump Part no Remarks
Short torx bolt149916-0400
(9 443 612 874)1
Long torx bolt149916-0300
(9 443 612 873)3
Holder
Bit
Head
side
Feed pump
side
Seal ring
AdviceMove the rotor backward and forward andleft and right with your finger and check thatit moves smoothly. If it does not movesmoothly, loosen the feed pump cover andthen retighten it to the specified torque.
(12) Insert the seal ring into the feed pump
cover.AdviceBe careful with the assembly orientation ofthe seal ring and ensure it is securelyassembled to the feed pump cover.
[2] Bearing reassembly(1) Assemble the holder to the bearing and
press the holder button (to hold the bearing).(2) Install the bearing in the pump housing.
P-VRZR- 085
Tool name Part no Remarks
Holder 157928-3620
Holder
Bearing
Pump housing
Button
AdviceEnsure the bearing is positioned correctly.
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REASSEMBLY
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[3] Timer piston reassembly(1) Assemble the slider in the timer piston.
P-VRZR- 086
(2) Assemble the timer piston and slider in thepump housing.
Advice
Align the slider hole with the timer pistonhole.
The slider is assembled in the timer withthe hole positioned toward the GEactuator side.
Note:The timer pistons low pressure side ispositioned toward where the Q adjustment ROMis installed.
P-VRZR- 087
[4] Cam ring reassemblyAssemble the cam ring in the pump housing.At this time, insert the cam ring pin into thetimer pistons slider hole.
AdviceConfirm that the timer piston slidessmoothly.
P-VRZR- 088
Slider
Timer piston
Timer piston
Pump housing
Cam ring
Pump housing
Cam ring pin
Slider hole
Timers low pressure side
Timers low pressure side
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REASSEMBLY
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[5] Drive shaft reassembly(1) Insert the holder into the bearing.(2) Press the holder button to hold the bearing
and pull the bearing into the head.AdvicePull the bearing into the head so that a gapremains between the feed pump cover andthe bearing.
(3) Insert the spacer into the pump housing.
P-VRZR- 089
P-VRZR- 090
P-VRZR- 091
Tool name Part no Remarks
Spacer 157928-4700
(4) Assemble the shim and the feed pumps
drive side key on the drive shaft.(5) Assemble the oil seal guide on the drive
shaft thread.Key
Shim
Oil seal guideDrive shaft
(6) Confirm that the seal ring is inserted intothe feed pump cover (see bottom figure ofpage 44).
(7) Align the drive shaft key with the feed pumprotor key groove and insert the drive shaftinto the feed pump.
AdviceInsert the drive shaft gently into the feedpump while turning it clockwise and counterclockwise to align the key with the keygroove.
P-VRZR- 092
Tool name Part no Remarks
Holder 157928-3620Holder
Spacer
Drive shaft
Pump housing
Spacer
Bearing
Tool name Part no Remarks
Oil seal guide 157928-4000For 25 diashaft
U-shaped
ring
Feed pump cover
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REASSEMBLY
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;
;
[6] Snapring reassembly(1) Remove the spacer from the pump housing.
AdviceConfirm that the drive shafts snapringgroove can be seen through the housingwindow.
P-VRZR- 094
(8) Lightly tap the drive shaft using a plastichammer to assemble the drive shaft with theend fully protruding from the drive side.
Advice When tapping the drive shaft with the
plastic hammer, ensure no burrs or dirtremain on the shaft.
Insert the drive shaft so that the end ofthe drive shaft is 1 ~ 2 mm higher thanthe end of the inner cam (when viewedfrom above).
After assembling the drive shaft, confirmthat the shaft rotates smoothly.
(3) Position the snapring in the drive shafts ringgroove and push it straight down.
(4) Remove the clip from the snapring and usethe end of the clip to push the snapring fullyinto the groove.
AdviceConfirm that the snapring is fully insertedinto the groove and that the drive shaft canbe rotated.
(2) Assemble the snapring to the clip.
P-VRZR- 095
P-VRZR- 096
P-VRZR- 093
Tool name Part no Remarks
Clip 157928-3120
Snapring
Clip
Plastic hammer
Pump housing
Spacer
Snapring
Clip AdvicePosition the snapring on the clip with theconvex face toward the clip.
Drive shaft
Inner cam
Drive shafts snapring groove
Convex face
1 ~ 2 mm
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REASSEMBLY
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P-VRZR- 097
[7] Adjusting drive shaft axial play(1) Position the distributor head on the pump
housing.AdviceDo not assemble the O-ring or the controlsleeve at this time.
(2) Install and tighten two diametrically opposedtorx bolts of the four to install the distributorhead.
Specified torque: 10.0 ~ 14.0 Nm{1.0 ~ 1.4 kgfm}
Tool name Part no Remarks
Measuring device 105782-4530
P-VRZR- 100
P-VRZR- 099
(3) Attach the measuring device to the drive
shaft.(4) Attach the dial gauge to the measuring
device.
P-VRZR- 098
(5) Measure the drive shafts axial play.
Specified value: 0.10.05 mm(with the head assembly installed)
(6) If not as specified, select shims from thetable on the following page and exchangethe shims until the axial play is as specified.(Refer to page 49.)
AdviceIf the axial play varies greatly from the
specified value, repeat procedure [5] on page46 and [6] on page 47.
Tool name Part no Remarks
Holder 157915-9820
Bit 157915-9600 T30
Measuring device
Distributor head
Pump housing
Torx bolts (2)
Bit
Holder
Drive shaft
Measuring device
Dial gauge
Drive shaft
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REASSEMBLY
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(7) Remove the dial gauge.(8) Remove the measuring device handle and
attach the extractor.
(9) Screw in the extractor to remove themeasuring device.
P-VRZR- 102
(10) Remove the torx bolts from the distributor
head.(11) Remove the distributor head from the
pump housing.
Tool name Part no Remarks
Extractor 157926-2421
P-VRZR- 101
P-VRZR- 103
RBAJ part no Bosch part no Thickness (mm)
149602-0000149602-0100149602-0200149602-0300149602-0400149602-0500149602-0600149602-0700149602-0800149602-0900149602-1000
9 443 612 8099 443 612 8109 443 612 8119 443 612 8129 443 612 8139 443 612 8149 443 612 8159 443 612 8169 443 612 8179 443 612 8189 443 612 819
1.901.952.002.052.102.152.202.252.302.352.40
[8] Selecting the rotor shaft shimPurposeThe rotor shafts axial play is measured and thenthe play is adjusted to the specified value usingthe shim.
Procedure 1 Adjusting the dial gauges 0point
(1) Insert the rotor shaft into the distributor head.
(2) Install the snapring in the rotor shaftssnapring groove.AdviceDo not assemble the shim at this time.
Snapring
Rotor shaft
Extractor
Distributor head
Pump housing
Distributor head
Measuring device
Shims
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REASSEMBLY
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P-VRZR- 104
(3) Attach the adapter to the head and thenattach the measuring device to the adapter.
P-VRZR- 105
Tool name Part no Remarks
Adapter 157845-8900
Measuringdevice
157829-3520 For measuringVE cam lift
(4) Pull the rotor shaft fully to the left and setthe dial gauge to the 0 position.
P-VRZR- 106
Procedure 2 C a l c u l a t i n g t h e s h i m
thickness(1) Push the rotor shaft fully to the right and
measure the full stroke from the dial gauge.AdviceThe rotor shafts groove must not catch onthe head.
P-VRZR- 107
(2) Select a shim using the formula below.Shim thickness = full stroke0.2 (mm)
RBAJ part no(key no. 53)
Bosch part noThickness
(mm)
149720-0000149720-0100149720-0200149720-0300
9 443 612 8519 443 612 8529 443 612 8539 443 612 854
2.12.22.32.4
(3) Install the selected shim and the snapring
to the rotor shaft.(4) After inserting the shim, confirm that thestroke is as specified. If not as specified,repeat Procedure 1 and Procedure 2.Specified stroke: 0.20.1 mm
Adapter
Measuring device
Head
Rotor shaft
Head
Head
Adapter
Adapter
Measuring device
Measuring device
Shim Snapring
Rotor shaft
Distributor head
Rotor shaft
Rotor shaft
Dial gauge
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REASSEMBLY
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P-VRZR- 108
(5) Remove the dial gauge and adapter fromthe head.
(6) Remove the snapring.
[9] TPS and timer cover reassembly(1) Assemble the TPS to the pump housing.Specified torque: 7.0 ~ 10.0 Nm
{0.7 ~ 1.0 kgfm}AdviceDo not mistake the positions of the TPSstandard point shim and the adjusting shim.
(2) Assemble the O-rings (at two locations) and
then assemble the high pressure side timercover on the pump housing.
Specified torque: 7.0 ~ 10.0 Nm{0.7 ~ 1.0 kgfm}
P-VRZR- 109
P-VRZR- 110
[10] Pump removalRemove the pump housing from bracket C.
Pump housing
TPS
Pump housing
Pump housing
Timer cover
Bracket C
TPS standard point shim
Adjusting shim
Core rod
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REASSEMBLY
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Cam ring
Timer piston
Cam link pin
Link plate
Timing link shaft ball pin
Control sleeve
Timing link shaft
Angle of cam rotation ()
VRZ pre-stroke (substitute)
Beginning of
cam lift
Beginning of pressure
delivery
Originalpre-stroke
Caml
ift(mm)
Pre-stroke adjustment values
2. PRE-STROKE ADJUSTMENT
Fundamentally, pre-stroke is the amount of lift from the cams bottom dead center position to thebeginning of pressure delivery position. With the VRZ pump, however, because it is not possibleto measure the cam lift with the pump assembled, the cam angle is instead measured from the
beginning of cam lift position to the beginning of pressure delivery position.The beginning of pressure delivery position can be changed by changing the phase (ie, the angle)between the cam link and the control sleeve, which are connected by the timing link shaft.Consequently, by changing the position of the link plate groove, we can change the phase of thecam link and the control sleeve to adjust the pre-stroke (ie, substituting the angle instead).
Pre-stroke adjustment sequence(1) Attach the measuring device to the pump.(2) Align the measuring devices measuring terminal with the standard cylinder Bs cam position.(3) Find the cams bottom dead center position using the dial gauge, then zero the dial gauge.(4) Rotate the pump in the specified direction of rotation and set the cam lift to 0.70 mm using the
dial gauge.(5) Set the 0 point using the KMA device to display cam lift as an angle.(6) Turn the pump back 10 in the direction opposite to the specified direction of rotation. Turn the
pump 5 in the specified direction of rotation (to prevent backlash).(7) Confirm that the dial gauge displays 0 mm.(8) Using the KMA device, reset the 0 point. (Using the KMA device, begin cam lift.)
P-VRZC- 034 P-VRZR- 315
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(4) Install the pre-stroke measuring device.Specified torque: 10.0 ~ 14.0 Nm
{1.0 ~ 1.4 kgfm}
Tool name Part no Remarks
Measuring device 105782-4540
[1] Measuring device installation
P-VRZR- 111
P-VRZR- 112
Drive shaft key position
for 4M41 model engine
Measuring device Drive shaftExisting bolts (2)
CAUTION
The pump test bench drive motor must beturned OFF.
Injury or damage may result if the pump testbench drive motor is turned ON.
Advice Align the drive shafts key groove and the
measuring devices measuring terminal
with the drive shaft. Ensure the end of the measuring device
is securely assembled to the drive shaftgroove.
P-VRZR- 316
FlangeInjection pump
Fixing stand Tool name Part no Remarks
Fixing stand 105796-0000 For 20NP
Flange 157811-9020 For VRZ
(1) Temporarily attach the fixing stand to thepump test bench and attach the injectionpump to the fixing stand.
(2) Align the key groove with the standardcylinder Bs pressure delivery cam positionas shown at left.
P-VRZR- 317
(3) Align the drive shaft key groove and the
measuring devices measuring terminal.Note: The pre-stroke can be measured on any
cylinder. Because the pump is set at thestandard cylinder B, however, measure thepre-stroke for this cylinder.
I f the dr ive shaft key groove and themeasuring devices measuring terminal arenot aligned, pre-stroke cannot be adjustedfrom cylinder B when the rotor shaft is
assembled.
Assembly position
of measuring
devices measuring
terminal
Drive shaft key groove
Measuring device
Measuring terminal
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(6) Move the fixing stand to assemble thecoupling teeth to the pump test bench drivecoupling.
AdviceEnsure approximately 1 mm axial clearancebetween the coupling and the drive coupling.
P-VRZR- 116
P-VRZR- 115
(7) Securely tighten the fixing stand installation
bolts and nuts and the drive coupling sockethead bolt to fix the injection pump to thepump test bench.
(8) Turn the pump test bench flywheel using thelever to confirm that the injection pumprotates smoothly.
(5) Assemble the key to the drive shaft. Alignthe coupling with the key, assemble it to thedrive shaft and then fix it using the nut.
Specified torque: 167 ~ 185 Nm{17.0 ~ 19.0 kgfm}
P-VRZR- 114
Fixing stand
Coupling
Fixing stand
Test bench drive coupling
Flywheel
Lever
CAUTION
Remove the lever after operating theflywheel.Operating the test bench without removing
the lever can cause serious injury anddamage the test bench.
Tool name Part no Remarks
Coupling 157847-0820 Shaft dia 25
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[2] Setting the 0 point for pre-strokeadjustment
(1) Turn the pump test benchs main switch ONand set the KMA (continuous measuringdevice) as described below. [Refer to theKMA (continuous measuring deviceoperation manual): Publication No EC18E-11091.]
Select the angle measurement display
Press F6 Select Settings
Press Enter Set the direction of rotationPress F2
P-VRZR- 164
Flywheel
P-VRZR- 118
Monitor display example
Dial gauge
angle measurement
F1 F2 F3 F4 F5 F6 F7 F8
1 2 4 5 63 7 8 10 11 129
(2) Turn the pump test bench flywheel in the
direction of pump rotation to find thestandard cylinders bottom dead centerposition on the measuring device dial gauge.(Refer to the data sheet for the standardcylinder.)
(3) Zero the dial gauge.(4) Turn the flywheel in the direction of rotation
so that the dial gauge reading is 0.7 mm.
P-VRZR- 117
Dial gauge
F2
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REASSEMBLY
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P-VRZR- 119
(5) Set the continuous measuring device asdescribed below.Press F2 Press both shift keys (press bothshift keys at the same time to activate anglecontrol) the monitor will display the dialog
position control unit error: control circuitopen) Press Enter the monitor displaywill change to(---.-) Press F6 Selectzero point setting Press Enter. (Thepump test bench angle measurement is nowset at 0.)
(6) To absorb backlash, turn the flywheel backat leas t 10 and then set the anglemeasurement display at 355 (ie, turn theflywheel back 5).
(7) Check that the dial gauge reading is 0mm.(8) Set the continuous measuring device asdescribed below.Press F6 Select zero point setting
Press Enter.(The pump test bench angle measurementis now set at 0.)
AdviceDo not alter the continuous measuringdevice angle measurement menu after this.Note:
The beginning of cam lift position is now set.
Flywheel
Measuring device
P-VRZR- 165
Monitor display example
(9) Remove the measuring device.
a n g l e m e a s u r e m e n t
F 1 F 2 F 3 F 4 F 5 F 6 F 7 F 8
1
0 . 0
5 6 2 4 3
P-VRZR- 120
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P-VRZR- 122
Tool name Part no Remarks
Holder 157915-9820
Bit 157915-9301 T20
(10) Remove the TPS from the pump housing.(11) Remove the timer cover from the pump
housing.
P-VRZR- 121
[3] Component reassembly(1) Rotor shaft reassembly(1) Select a forked plate as described below and
then assemble the plate.Selecting a forked plate
Head assembly Cam ring Forked plate marked G
Replaced Replaced Replaced
ReplacedNot
replacedReplaced
Not replaced Replaced Replaced
Not replacedNot
replacedDo not replace (use theinstalled forked plate)*
* If the installed forked plate fork is worn,assemble a forked plate marked G.(Refer to the table on page 67.)
Specified torque: 3.0 ~ 5.0 Nm{0.3 ~ 0.5 kgfm}
(2) Rotate the drive shaft so that the rotor shaft
pin is positioned toward the GE actuator asshown at left.
Note:The rotor shaft does not contact the forked pate.(3) Remove the clip from the rotor shaft.
P-VRZR- 123
Forked plate
Holder Bit
Tool name Part no Remarks
Clip 157971-0500
Timer cover
Pump housing
TPS
Clip
Spring
(4) Assemble the radial plungers, the rollershoes and the rollers to the rotor shaft.
(5) With the spring assembled to the rotor shaft,
assemble the rotor shaft assembly to thedrive shaft groove.
AdviceDo not drop the roller shoes or the rollers.
Rotor shaft assembly
Drive shaft
Rotor shaft
Rotor shaft pin
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P-VRZR- 124
(2) Distributor head assembly reassembly(1) Assemble the O-ring on the distributor head.(2) Assemble the control sleeve in the
distributor head.Advice
The face with the larger chamfer ispositioned toward the head.
(3) Assemble the distributor head assembly tothe rotor shaft.
(4) Tighten diagonally opposed torx bolts to
loosely install the distributor head.AdviceDo not tighten the distributor head assembly.Leave it loose.(5) Assemble the distributor head assembly to
the pump housing.AdviceMove the timer piston to align the forkedplate groove with the distributor headassembly pin.
P-VRZR- 126
(6) Move the timer piston and confirm that thecontrol sleeve rotates, and then graduallytighten two diametrically opposed torx bolts.
(7) If the timer piston does not move smoothly,loosen the torx bolts and repeat procedure(6) above.
Note:If the timer piston does not move smoothly, thecontrol sleeve will not move smoothly, the pinmay not engage the plate when the head istightened, and either the plate or the pin may
be damaged.(8) Tighten the torx bolts until the distributor
head assembly is securely tightened to thepump housing.
P-VRZR- 125
Distributor head
Pump housing
Distributor head
Control sleeve
Large chamfer Small chamfer
Head side
Pump housing
Distributor head
Torx bolts
O-rings (2)
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(10) Assemble the shim and snapring to therotor shaft.
(11) Install the plug to the distributor head
together with a new O-ring.
P-VRZR- 128
(9) Install the other two torx bolts and thentighten all four torx bolts to the specifiedtorque.
Specified torque: 10.0 ~ 14.0 Nm{1.0 ~ 1.4 kgfm}
(12) Tighten the plug using a hexagon wrench
(SW14mm).Specified torque: 20.0 ~ 29.0 Nm
{2.0 ~ 3.0 kgfm}
(3) CPV holder reassembly(1) Assemble the gaskets and CPV holders to
the distributor heads cylinders A, C and D.AdviceThe CPV holders must be reassembled tothe distributor head in their original positionsA, C and D marked on the head.(2) Assemble the dummy holder and gasket to
the distributor heads cylinder B.
P-VRZR- 130
P-VRZR- 127
P-VRZR- 129
Tool name Part no Remarks
Holder 157845-9500Part of pipe assembly157845-9520.
Tool name Part no Remarks
Holder 157915-9820
Bit 157915-9600 T30
Torx bolts (4)
Holder
Bit
Snapring
Shim
O-ring
CPV holders (3)
Distributor head
Plug
Plug
Gaskets (4)
Hexagon wrench
Dummy holder
Cylinder B
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(5) Timer cover and TPS (timer pistonsensor) reassembly
(1) Assemble the timer cover and the small andlarge O-rings (new) to the high pressure side.(See below for the assembly procedure.)
P-VRZR- 135
P-VRZR- 136
(2) Push the small O-ring securely into the pumphousing using your finger.
(3) Push the large O-ring securely into the timer
cover using your finger and install the timercover using the torx bolts.
Specified torque: 7.0 ~ 10.0 Nm{0.7 ~ 1.0 kgfm}
(6) Secure the TPS to the pump housing usingthe torx bolts and a socket wrench (M6).
Specified torque: 7.0 ~ 10.0 Nm{0.7 ~ 1.0 kgfm}
P-VRZR- 137
(4) Assemble the TPS standard point shim, the
core rod, the timer spring and the timerstroke adjusting shim in the pump housing.
AdviceDo not mistake the assembly positions of theTPS standard point shim and the timer strokeadjusting shim.(5) Assemble the TPS to the pump housing.AdviceEnsure the O-rings are not damaged.
P-VRZR- 138
Tool name Part no Remarks
Holder 157915-9820
Bit 157915-9600 T30Holder
Bit
T imer
cover
Large O-ringSmall O-ring
Torx bolts (2)
Pump housing
TPS
Core rod
Timer spring
Timer stroke
adjusting shim
O-ring
Pump housing
Timer
cover
Pump housing
Socket wrench
TPS
Torx bolts (2)
Standard point shim
Large O-ring
Small O-ring
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(3) Assemble the GE actuator pin in the controlsleeve groove.
(4) Move the GE actuator in an axial directionas shown by the arrow in the figure at leftand confirm that the actuator moves
smoothly.Advice Do not force the GE actuator. Forcing it
may damage the seal ring. The GE actuator will not move if its pin
is not inserted into the control sleevegroove. If it will not move, remove theGE actuator and again insert the pin intothe groove.
(5) Move the GE actuator fully toward the full
side (ie, the head side).AdviceIf the GE actuator is positioned toward thedrive shaft side, it may not be possible tomeasure the pre-stroke.
(6) Secure the GE actuator to the pump housingusing the torx bolts.
AdviceTighten diagonally opposed torx boltsgradually and uniformly to the specifiedtorque.Specified torque: 7.0 ~ 10.0 Nm
{0.7 ~ 1.0 kgfm}
Tool name Part no Remarks
Holder 157915-9820
Bit 157915-9600 T30
P-VRZR- 143
P-VRZR- 144
P-VRZR- 145
P-VRZR- 146
GE actuator
GE actuator
GE actuator pin
Holder
Pump housing
Torx bolts (6)
Bit
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(8) Magnet valve assembly installation(1) Install the magnet valve assembly to the GE
actuator.AdviceEnsure the filter is installed securely.
P-VRZR- 147
P-VRZR- 148
(2) Tighten the magnet valve assembly using atorque spanner.
Specified torque: 20.0 ~ 25.0 Nm
{2.0 ~ 2.5 kgfm}
(9) Pre-stroke adjustment
(1) Connect the fuel hose to the injection pumpusing the adapter.
P-VRZR- 149
P-VRZR- 150
(2) Install plugs to where the distributor headand GE actuator overflow valves wereremoved.
AdviceInstall any suitable plugs to maintain pumpchamber air tightness.
Tool name Part no Remarks
Adapter 157977-8000
Gasket 026512-1640
Magnet valve assembly
Magnet valve assemblyGE actuator
Spanner
Hose
Adapter
Injection pump
Plugs
Gaskets (2)
Armature
O-ring
Spring
Gauze filter
Magnet valve
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Tool name Part no Remarks
Pipe assembly 157845-9520
(3) Remove cylinder Bs delivery valve holderand assemble the pipe assembly to cylinderB.
(5) Turn the pump test bench drive switch ON.
(6) Supply test oil to the injection pump at thespecified pressure (20.0 kPa {0.2 kgf/cm2}).
AdviceLeave the drive switch ON. Do not turn thedrive switch OFF until pre-stroke adjustmenthas been completed.
P-VRZR- 153
(7) Turn the pump test bench flywheel aboutone turn in the specified direction of rotationusing the lever and use the anglemeasurement display to confirm that it turnssmoothly.
P-VRZR- 154
P-VRZR- 152
P-VRZR- 151
(4) Connect the direct current harness to themagnet valve.
Advice
Magnet valve supply voltage 12V specification: 12V
Injection pump
Lever
Flywheel
Magnet valve assembly
Pipe assembly
Direct current harness
Cylinder B
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REASSEMBLY
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Forked plates for 4 cylinders
(12) Tighten the CPV holder using a socketwrench.
Specified torque: 44.0 ~ 54.0 Nm{4.5 ~ 5.5 kgfm}
Tool name Part no Remarks
Socket wrench 157914-3600
P-VRZR- 159
(11) Remove the pipe assembly from cylinder
B and replace it with the CPV holder.Replace the gasket at the same time.
P-VRZR- 158
CPV holder
(13) Remove the plugs.
RBAJ part no Bosch part no Stamping Pre-stroke variation ()
149615-0001 9 443 612 824 A -3.03
149615-0101 9 443 612 825 B -2.50
149615-0201 9 443 612 826 C -1.97
149615-0301 9 443 612 827 D -1.43
149615-0401 9 443 612 828 E -1.07
149615-0501 9 443 612 829 F -0.54
149615-0601 9 443 612 830 G 0
149615-0701 9 443 612 831 H 0.54
149615-0801 9 443 612 832 I 1.07
149615-0901 9 443 612 833 J 1.43
149615-1001 9 443 612 834 K 1.97
149615-1101 9 443 612 835 L 2.50
149615-1201 9 443 612 836 M 3.03
Plugs
Socket wrench
CPV holder
Cylinder B
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ADJUSTMENT
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1. ADJUSTMENT CONDITIONS[1] Test equipment(1) Pump test bench EPS815(2) KMA802(3) Oil cooler (1 687 010 130)(4) Adjustment software operating environment
[2] Fuel piping(1) Injection system piping diagram
Nozzle and nozzle holder assembly (1 688 901 035) Tubes
Joint assembly (157641-6820)Injection pipes (157808-4720) P-VRZR- 390
Cooling unit
Injection tubes
Windows OSWindows 2000 PRO (at least Service Pack 2.0) English language version;Control Panel - Regional Options, Your locale: English (United Kingdom or United States)
Clock speed Personal computer equipped with Pentium CPU (clock speed at least 333 MHz)
Memory At least 128 MB usable memory
Hard disk At least 20 MB space
Display Resolution: at least 1027 x 768, number of display colors: high color minimum (16 bit)
Drive devices CD-ROM drive, floppy disk drive
Additional devicesAt least 2 communication ports (2 necessary for controller assembly)Mouse, keyboard
Note:Refer to the Installation Manual, MC-02 TESTER SOFTWARE, ADJUSTMENT AND INSPECTIONDATA, Publication No. ED14E-11011, for details of personal computer settings and softwareinstallation procedures.
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ADJUSTMENT
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Key no RBAJ part no Bosch part no Part name Qty Remarks
1
1/1
1/2
1/3
1/4
1/5
1/6
1/7
157971-1020
157971-1100
026512-1640
029711-2180
157971-1000
017211-2010
157986-8100
026510-1340
9 443 613 442
9 443 613 443
9 421 617 041
9 442 610 444
9 443 613 444
9 442 611 983
9 443 613 445
9 442 610 043
Piping assembly
Bolt
Gasket
Eye
Adapter
Hose clip
Hose
Gasket
-
1
6
2
1
2
1
1
For VRZ overflow fuel piping
For distributor head overflow
For distributor head overflow
For distributor head overflow
For distributor head overflow
For distributor head overflow
For distributor head overflow
For distributor head overflow
Piping outline
Overflow measurement hose
P-VRZR- 391
(2) Fuel piping
Multi-way cock
Test oil hose
Temperature sensor cable
1/2
1/2
1/1
1/41/5
Pump chamber pressure
measurement hose
Pressure gauge
1/3
1/6
1/5
1/7
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ADJUSTMENT
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[3] Wiring outline(1) Controller assembly wiring
(2) Wiring connections inside controller unit
PC
COM2 COM1
RS232CCOM225 pin
RS232CCOM29 pin
ROM writer
ECUlamp
ECUlamp
ECUlamp WL
(COVEC-F)ECU
4M41(VRZ)ECU
4D56(COVEC-F)
ECU
ROMcable
Maincable
Maincable
Maincable
ROM
GE
CSP
TPS
TCV
TF
FCV
FCV lineFCV line
FCVswitch
FCV switch
FCV lineFCV switch
Selectorswitch
12
3
4
0
Sub-switch
ROMlamp
DC 5VConstant
power supply
DC 24VConstant
power supply
DC 12VConstant
power supply
Powerlamp
Main powerswitch
ACsocket
AC100 - 120V200 - 240V
VRZ & COVEC-F (ROM) CONTROLLER
Injectionpump
P-VRZR- 395
P-VRZR- 392
ROM harness
(157966-5020)
Personal computer
Tool connection 232C cable
Connection: straight connection
(157966-4620)
Tool connection 232C cable
Connection: cross connection (2 pin, 3 pin cross)
(157966-4720)
Dsub 9 pin
Injection pump
Main harness
(157966-4920)
Dsub 25 pin
Dsub 7 pin
VRZ and COVEC-F
controller unit
Dsub 9 pin
Earth to injection pump
or pump test bench
To AC100V - AC120V or
AC200V - 240V power source
(157966-4420 or 157966-4520)
Intermediate harness
(157966-2421) Intermediate harness
(157966-5720)
FCV GND harness
(157966-4820)
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ADJUSTMENT
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No. Publication No. Remarks
1 ED14E-11021When installing the ECU assembly for the controller unit, refer to the installationinstructions included with the controller unit.
2 ED14E-11011When installing the adjustment software, refer to the installation manual included with theCD-ROM.
[4] Related materials
Note:Where updating of adjustment data and inspection data is indicated, copy the data from the ESPI(ZW)s CD-ROM.
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ADJUSTMENT
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Keyno
Name Use and purpose
11 ECU changeover switch
Turn to align with ECU in use.0: All OFF1: No. 1 ECU
2: No. 2 ECU3: No. 3 ECU4: Spare ECU
12 Sub-switchPower sub-switch for controller unit for VRZ adjustment. Press once to turn ON.When turned ON for use, orange lamp lights. Press once again to turn OFF.
13 ROM pilot lamp Green lamp lights when ROM in use.
14ROM wire harness connectingterminal
For connecting injection pump's ROM harness connector to ROM controllerusing wire harness.
If you smell any unusual smell or see smoke or sparks when using the controller unit, turn thepower switch OFF immediately and stop using the controller unit.Fire may result if you continue to use the controller unit.
Advice
Do not use the controller unit with oily hands. The oil may stick to the dials and causeimproper resistor contact inside the controller unit, preventing proper operation.
Before turning the power switch ON, confirm that the wire harnesses are properlyconnected.
CAUTION
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ADJUSTMENT
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Keyno
Name Use and purpose
1 AC100V - 120V power orAC 200V - 240V power terminal
Connect to AC100V - 120V, 50/60Hz power source orAC 200V - 240V power source, 50/60Hz.
2 Main switch (breaker)Controller unit power switch.
Turn ON when in use (position at 'I'). Position at 'O' to turn OFF.
3D-sub 9 pin cable connection(COM1)
Connects RS232C cable to personal computer (for GE).
4D-sub 25 pin cable connection(COM2)
Connects RS232C cable to personal computer (for Q-ROM)
[2] Rear panel
If you smell any unusual smell or see smoke or sparks when using the controller unit, turn thepower OFF immediately and stop using the controller unit.Fire may result if you continue to use the controller unit.
CAUTION
CE
4
2
3
1
Advice
Do not use the controller unit with oily hands. The oil may stick to the dials and causeimproper resistor contact inside the controller unit, preventing proper operation.
Before turning the power switch ON, confirm that the wire harnesses are properlyconnected.
P-VRZR- 345
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-
75-
2. ECU selection
[1] 4D56
[2] 4M41
[3] WL[4] Manual operation
[5] Workshop name registration
[6] Exit
Part no. input
[1] Adjustment
[2] Inspection
Agreement
[1] or [2] or [3] [4] [5]
Disagreement
1. Password input
Input item
[1] Workshop name
[2] Address
[3] Telephone[4] Fax
[5] Operator's name
[6] Password
Push [MENU] button(= Registration change
completed)
Step 1-XX Adjustment
StepXX + 1 ROM compensation
StepXX + 2 ROM writing
Adjustment
Step 1-XX Inspection
Inspection
Adjustment result
OK
Repeatmeasurement
Print result Cancel
Final confirmation
Pre-check 1.
Manual operation
Inspection result
OK Repeatmeasurement
Print result Cancel
OK
Final confirmation
Select "Registration" butto
Confirmation
Workshop name registrati
P-VRZR-396
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ADJUSTMENT
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Exit
Workshop name registration
Manual operation
ROM COVEC-F MITSUBISHI 12VInspection/adjustment
VRZ MITSUBISHI 12VInspection/adjustment
ROM COVEC-F MAZDA 12VInspection/adjustment
RBAJService tools for pump adjustment Version1.0Copyright(C) 2001-2003 by Bosch Automotive Systems Corporation
MC-02 TESTER
4. PUMP ADJUSTMENT TOOL MONITOR SCREEN
No. Name Use and purpose
1 4D56 model engine's COVEC-F typeinjection pump inspection / adjustment key
Select for inspection / adjustment of COVEC-F injection pump forMitsubishi 4D56 model engine
2 4M41 model engine's VRZ type injectionpump inspection / adjustment key
Select for inspection / adjustment of VRZ injection pump forMitsubishi 4M41 model engine
3 WL model engine's COVEC-F typeinjection pump inspection / adjustment key
Select for inspection / adjustment of COVEC-F injection pump forMazda WL model engine
4 Manual operation key For adjusting injection pump and engine's installation timing
5 Workshop registration key For workshop registration
6 Exit key To exit adjustment software
5
4
3
6
2
1
P-VRZR- 346
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ADJUSTMENT
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5. PUMP ADJUSTMENT TOOL MONITOR SCREEN OUTLINEInspection and adjustment step screen
Pump adjustment tools for service Input part no.Inspection and adjustment steps
monitor screen
0N r/min44-666644-3032
000000000b00000-000-0000b
VRZ 4M41
VRZ(12V)
MELCO
Pump information
MENU
2001-01-15 11:28:44
0.0T
V
Sequence
No. STEP N
03
03 / 32
1000rpm
Soll
2.91v
Soll-cor
0.00mv
TCVF
60Hz
DTCV
100%
04 500rpm 2.50v 60Hz 0%
0.000
0.0
Pt MPa
Qo l/h
TF V
0.0Q
VTPS V
TPS V
TA mm
0.0DQ
Ua-ist
deg C
mm /st3
Rotation
ECU
Right
4 cylinders
Mode
Pump type
Adjustment
Part number input
Zero set
Soll-cor
Step information
Step status
Next
Comment
Select
PT standard point
After values are input, push 'Next' button.
P_cham_ADJ
mm /st3
215
9
8
4
3
7
6
2
1
14
10
15
11
16
12
17
13
18
20
19
22
23
24
25
Only items necessary for each
step are displayed.
Back Next
Circled numbers indicate fields
where input is necessary.
P-VRZR- 347
No. Name Use and purpose
1 Pump speed input N: pump speed Input the pump's speed.
2 Test oi l temperature input T: test oi l temperature Input the test oi l temperature.
3 Actual control sleeve position voltagedisplay
U soll: actual control sleeve positionvoltage
Displays actual control sleeve position voltage.
4 Pump injection quantity input Q: pump injection quantity Input pump's injection quantity.
5 Pump chamber pressure input Pt: pump chamber pressure Input pump's chamber pressure.
6 Pump overflow quantity input Qo: pump overflow quantity Input pump's overflow quantity.
7 TF output display TF: fuel temperature Displays fuel temperature output voltage.
8 VTPS output display VTPS: voltage at 0 mm timer stroke Displays VTPS output voltage (voltage at 0 mm timer stroke).
9 TPS output display TPS: timer piston sensor output voltage Displays TPS (timer piston sensor) output voltage.
10 TA output display TA: timer stroke Displays TA (timer stroke) output.
11 Variation between cylinders display DQ: variation between cylinders Input pump's variation between injection quantities.
12 Zero setting key TPS output voltage at TA = 0 mm can be set at 0 V.
13 Target control sleeve position
compensation voltage key
Any control sleeve position can be set by setting the compensation
voltage.14 NEXT key To set at next step.
15 Keys for moving to next or previous step To set at any step ( BACK, NEXT).
16 Menu key To set at MENU display.
17 Part number input key To set at part number input display.
18 Step status display Displays step status. Changes from red to green when all itemsare within specifications.
19 Part number, serial number display Displays pump information part number (specifi cation, pump) andserial number (pump, GE).
20 Specification display Displays pump information specifications.
21 Measurement mode display Displays pump information measurement mode (inspection,adjustment).
22 Measurement date display Displays date and time of measurements.
23 Status display Displays step status. Green: within specifications; red: outside ofspecifications.
24 Current step display Displays current step items.
25 Next step display Displays next step's items.
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ADJUSTMENT
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GE Soll
Item UnitValue
Item UnitValue
ECU reader data
ECU configuration data
1. Values must be input for GE soll, TCV Duty and TCV Frequency.2. Np values do not appear at VRZ pump adjustment.
Input
Select ECU
GE Vist V
Item UnitValue
VTPS Vist
Item UnitValue
r/minNpTF deg C
V
GE Soll-cor mV
TCV Duty %
TCV Frequency Hz
Initialize ECU
Menu
Manual operationMC-02 TESTER
ROM COVEC-F MITSUBISHI 12V VRZ MITSUBISHI 12V ROM COVEC-F MAZDA 12V
6. MANUAL OPERATION DISPLAYSecond timing adjustment (manual operation)
Pump adjustment tools for service Second timing adjustment (manual operation)
No. Name Remarks
1 Control sleeve position actual voltagedisplay
Displays actual control sleeve position voltage.
2 Control sleeve position target voltagedisplay
By operating the input keys, the control sleeve position can be setfor the engine specified in No. 5.
3 Initialize ECU Clear display values
4 MENU Displays MENU screen.
5 Select ECU Select the ECU for the engine.
1
2
3
4
5
P-VRZR- 348
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ADJUSTMENT
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Menu Registration
Input items and select Registration button.
Workshop name RBAJ
Address JAPAN
Telephone 000-000-0000
Fax 111-111-1111
Operator's name sse
Password ****
Workshop name registrationMC-02 TESTER
Exit
Workshop name registration
Manual operation
ROM COVEC-F MITSUBISHI 12VInspection/adjustment
VRZ MITSUBISHI 12VInspection/adjustment
ROM COVEC-F MAZDA 12VInspection/adjustment
RBAJService tools for pump adjustment Version1.0Copyright(C) 2001-2003 by Bosch Automotive Sys tems Corporation
MC-02 TESTER
Menu Registration
Input items and select Registration button.
Workshop name RBAJ
Address JAPAN
Telephone 000-000-0000
Fax 111-111-1111
Operator's name sse
Password ****
Workshop name registrationMC-02 TESTER
7. WORKSHOP DISPLAYSecond timing adjustment (manual operation)
Pump adjustment tools for service Workshop name registration
No. Name Remarks
1 Workshop name Input comany name.
2 Address Input company address.
3 Telephone Input telephone number.
4 Fax Input fax number.
5 Operator's name Input operator's name.
6 Password Input password and change password.
7 MENU Can be used to set MENU display.
8 Registration For keeping registered items.
1
3
4
56
P-VRZR- 350
7
2
8
(1)
(3)
(2)
P-VRZR- 346
P-VRZR- 350
WORKSHOP REGISTRATION(1) Select Workshop name registration.
(2) Input the company name, etc, in the fieldson the screen.
(3) Click the Registration button.Note:The default password at setup is RBAJ.Input a new password if desired. (The only limitto the number of figures and letters in thepassword is the size of the input field.)
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ADJUSTMENT
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8. ADJUSTMENTAdjustment sequence
Preparation
Pre-stroke adjustment
Pump chamber pressure adjustment
Timer stroke and characteristic confirmation
Pump chamber pressure confirmation
Magnet valve operation confirmation
Finish
Standard injection quantity point adjustment
Non-injection confirmation
Injection quantity compensation point adjustment
Compensation ROM interpolation calculation
Writing to the compensation ROM
Second timing adjustment
Part no. input and installation confirmation
Warming-up operation
Recording the pump and GE serial numbers See page 81 [1]
See page 81 [2], 82 [3]
See page 88 [11]
See page 83 [4]
See page 64 (9)
See page 84 [5]
See page 85 [6]
See page 86 [8]
See page 88 [10]
See page 86 [7]
See page 89 [12]
See page 89 [13]
See page 90 [14]
See page 90 [15]
See page 94 (4)
See page 87 [9] TPS zero setting
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ADJUSTMENT
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Password is required to actuate adjustment tools.
Input password and press ENTER key.
Precaution
MC-02 TESTER
(8) Reconfirm that the coupling and the fixingstand bolts and nuts are securely tightened.
(9) Set the 20NP pump test benchs test oiloutlet temperature at 45C.
(10) Set the cooling unit oil delivery pressure
lever at 80 kPa {0.8 kgf/cm2} or less.
(11) Connect the wire harness to the controllerunits No 2 ECU connector.
(12) Turn the main switch on the rear of the
controller unit ON.(13) Set the No 1 ~ No 4 changeover switch at
No 2.(14) Turn the FCV (magnet valve) ON/OFF
switch ON to energize the magnet valve.(15) Turn the sub switch on the front of the
controller unit ON.
[3]Adjustment software set up:preparation
(1) Turn the computer and the monitor powerswitches ON.
(2) Start the Service tools for pump adjustmentsoftware.
(3) Input the password and press the Enter key.AdviceInput the initial default password RBAJ oryour own password.
Fixing stand
FCV (magnet valve) ON/OFF switch
E C U f o r V R Z t y p e
injection pump
Sub-switch
No. 1 ~ No. 4 changeover switch
Monitor power switch
Computer power switch
(3)
P-VRZR- 355
P-VRZR- 397
P-VRZR- 210
P-VRZR- 357
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ADJUSTMENT
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Menu
4. Operation sequence
3. Adjustment controller wiring
2. Overflow piping
1. Injection system piping
Back Next
Installation confirmationClick on appropriate itemand explanatory illustration is displayed.
If necessary to proceedafter confirmation, push Next button.
Setup confirmationMC-02 TESTER
Key no.
1
2
3
4
Part name Part no. Note
Injection pipe
Nozzle & nozzle holder assembly
Joint
Injection tube
157808-4720
1 688 901 035
Same as VP44
4
3
2
1
Menu NextClear
If number input is correct, select Next button.If you need to input a different number, select Clear button.
446613
443062
System specifications
Pump serial no.(10 digits)
GE serial no.(13 digits)
Specified part no.(6 digits)
Pump part no.(last 6 digits)
0880052496
5062008852056
Engine model VRZ_4M41Rotation Right
Pump cylinders 4 cylindersECU MELCO
Mode Adjustment
Part number inputMC-02 TESTER
1. Specified part no.
2. Pump part no.Example:
Full pump no.
109144-3052
104700-0551
Input pump part no.
443052
000551
Pumppart no.
104700-304*
104700-305*
104700-306*
109144-305*
109144-306*
104700-055*
Pumptype OEM
Specified part no.
COVEC-F
VRZ
COVEC-F
003040
003051
003060
008040
008051
008060
44-6613 44-8813
008550000550MAZDA
MITSUBISHI
Adjustment Inspection
Exit
Workshop name registration
Manual operation
ROM COVEC-F MITSUBISHI 12VInspection/adjustment
VRZ MITSUBISHI 12VInspection/adjustment
ROM COVEC-F MAZDA 12VInspection/adjustment
RBAJService tools for pump adjustment Version1.0Copyright(C) 2001-2003 by Bosch Automotive Syst ems Corporation
MC-02 TESTER
[4] P a r t n um b e r i n p u t a n dconfirmation
(1) Select the VRZ [Mitsubishi 12V] Inspection/adjustment button.
(2) When the dialog shown at left appears, inputthe specified part number (6 digits) andpress Enter.
(3) Input the pump part number (last 6 digits)and press Enter.
(4) Input the pump serial number (10 digits) andpress Enter.
(5) Input the GEs serial number (13 digits) andpress Enter.
(6) Press the Next key.
(7) Confirm that the screen changes to the
injection system piping display.Note:Clicking the different buttons (1. Injection systempiping, 2. Overflow piping, 3. Adjustmentcontroller wiring, and 4. Operation sequence)displays different Setup confirmation screens.
(2)
(3)
(4)
(5)
(1)
(6)
P-VRZR- 346
P-VRZR- 358
P-VRZR- 359
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ADJUSTMENT
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Next
Step status
Status Item Unit Specification ToleranceMeasured / input value
0N r/min
deg C
After values are input, push Next button.Sequence
Present stepNo. S tep name N
02
02 / 31
1000r/min
Soll
2.91v
Soll-cor
0.00mv
0.00mv
Frequency
60Hz
Duty
100%Warm-up
03 1000r/min 2.91v 60Hz 100%P-cham_ADJ
Warm-up
Select
Comment
Specifiedpartno.
Pump part no.
Pump serial no.
GE serial no.
Engine model
Rotation
Mode
Pump type
Pump cylinders
ECU
44-6613
44-3062
0880052496
50620-088-52056
VRZ_4M41
Right
Adjustment
VRZ (12V)
4 cylinders
MELCO
Pump information
Step information
Menu Part number input
05/04/03 13:21:45
0.0
0.0
T
Ua-ist V
Q
Service tools for pump adjustment Adjustment display
3mm /st
Next
Step status
Status I tem Unit Specification ToleranceMeasured / input value
0N r/min
deg C
After values are input, push Next button.Sequence
Present stepNo. S tep name N
01
01 / 31
300r/min
Soll
2.80v
Soll-cor
0.00mv
0.00mv
Frequency
60Hz
Duty
100%Warm-up
02 1000r/min 2.91v 60Hz 100%Warm-up
Check for fuel leaks.
Select
Comment
Specifiedpartno.
Pump part no.
Pump serial no.
GE serial no.
Engine model
Rotation
Mode
Pump type
Pump cylinders
ECU
44-6613
44-3062
0880052496
50620-088-52056
VRZ_4M41
Right
Adjustment
VRZ (12V)
4 cylinders
MELCO
Pump information
Step information
Menu Part number input
05/04/03 13:20:52
0.0
0.0
T
Ua-ist V
Q
Service tools for pump adjustment Adjustment display
3mm /st
[5] Warming-up operation(1) Set the pump test bench delivery pressure
at the specified 40 kPa {0.4 kgf/cm2}.(2) Confirm that the sequence is 01/31.(3) Run the injection pump at the specified
speed N (see figure at left).(4) Measure N, T and Q on the pump test bench
and input the values.Note:U ist is displayed automatically.(5) Confirm that the Step status field is green.(6) Proceed to the next step.AdviceIf U ist values are not as specified, pressthe Next button several times. Then, return
to Step 01/31 using the back arrow.Repeat the Step 01/31 and confirm that U ist values are as specified.Note:If not as specified after confirming U ist severaltimes, the GE may be faulty.
(7) Confirm that the sequence is 02/31.
(8) Run the injection pump at the specifiedspeed N (see figure at left).
(9) Measure N, T and Q on the pump test benchand input the values.
Note:U ist is displayed automatically.(10) Confirm injection.(11) Confirm that no fuel leaks from the
injection pump fuel piping connections.
CAUTION
If there are any fuel leaks, if there is noinjection or if any unusual noises occurduring operation, stop test bench operationimmediately and inspect the pump.
(12) Confirm that the injection pump isoperating normally.
(13) Confirm that the Step status field is green.(14) Proceed to the next step.AdviceBecause the test oil temperature takeslonger to increase in cold weather, turn thepump test bench on earlier.
P-VRZR- 360
P-VRZR- 361
(2)
(5)
(7)
(6)
(13)
(14)
(4)
(9)
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ADJUSTMENT
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Next
Step status
Status I tem Unit Specification ToleranceMeasured / input value
0N r/min
deg C
After values are input, push Next buttonSequence
Present stepNo. S tep name N
05
05 / 31
1000r/min
Soll
2.91v
Soll-cor
0.00mv
0.00mv
Frequency
60Hz
Duty
100%P-cham_ADJ
06 500r/min 2.50v 60Hz 100%Zero_set
Reconfirmation of PT standard point
Select
Comment
Specifiedpartno.
Pump part no.
Pump serial no.
GE serial no.
Engine model
Rotation
Mode
Pump type
Pump cylinders
ECU
44-6613
44-3062
0880052496
50620-088-52056
VRZ_4M41
Right
Adjustment
VRZ (12V)
4 cylinders
MELCO
Pump information
Step information
Menu Part number input
05/04/03 13:23:42
0.0
0.000
T
Ua-ist V
I/h0.0Qo
TF V
Pt MPa
Service tools for pump adjustment Adjustment display
Next
Step status
Status I tem Unit Specification ToleranceMeasured / input value
0N r/min
deg C
After values are input, push Next button.Sequence
Present stepNo. S tep name N
04
04 / 31
1000r/min
Soll
2.91v
Soll-cor
0.00mv
0.00mv
Frequency
60Hz
Duty
100%Rough-Q_ADJ
05 1000r/min 2.91v 60Hz 100%P-cham_ADJ
Standard Q adjustment (GE adjustment)
Select
Comment
Specifiedpartno.
Pump part no.
Pump serial no.
GE serial no.
Engine model
Rotation
Mode
Pump type
Pump cylinders
ECU
44-6613
44-3062
0880052496
50620-088-52056
VRZ_4M41
Right
Adjustment
VRZ (12V)
4 cylinders
MELCO
Pump information
Step information
Menu Part number input
05/04/03 13:23:05
0.0
0.0
T
Ua-ist V
0.0DQ
Q
Service tools for pump adjustment Adjustment display
mm /st3
3mm /st
[7] Standard injection quantity pointadjustment
(1) Confirm that the sequence is 04/31.(2) Run the injection pump at the specified
speed N (see figure at left).(3) Measure N, T, Q and DQ on the pump test
bench and input the values.Note:U ist is displayed automatically.(4) If Q is as specified, perform steps (9) and
(10). If Q is not as specified, adjust asdescribed below.
[ 8 ] P u m p c h a m b e r p r e s s u r e
confirmation(1) Confirm that the sequence is 05/31.(2) Run the injection pump at the specified
speed N (see figure at left).(3) Measure N, T, Pt and Qo on the pump test
bench and input the values.Note:U ist and TF are displayed automatically.(4) Confirm the pump chamber pressure.(5) Confirm that the Step status field is green.(6) Proceed to the next step.
AdviceRecheck the feed pump.
(3)
(1)
(9)
(10)
(3)
(5)
(6)
P-VRZR- 363
P-VRZR- 355
P-VRZR- 364(1)
Injection quantity decrease
(move GE actuator toward drive side)
Injection quantity increase
(move GE actuator toward
distributor head side)
GE actuator
Move GE actuator to adjust
(5) To adjust the fuel injection quantity, loosenthe torx bolts so that the GE actuator canmove a little.
(6) Move the GE actuator in the drive shaftsaxial direction to adjust the full load injectionquantity. (To increase the injection quantity,move the GE actuator toward the distributorhead. To decrease the injection quantity,move the GE actuator toward the drive side.)Record the measured injection quantity andthe position of the GE actuator to facilitateadjustment.
(7) Following adjustment, tighten the torx bolts
to the specified torque.Specified torque: 7 ~ 10 N.m{0.7 ~ 1.0 kgf.m}
(8) Measure N, T, Q and DQ again on the pumptest bench and input the values.
(9) Confirm that the Step status field is green.(10) Proceed to the next step.
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91/117
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ADJUSTMENT
- 88 -
Next
Step status
Status I tem Unit Specification ToleranceMeasured / input value
0N r/min
deg C
After values are input, push Next button.Sequence
Present stepNo. S tep name N
17
17 / 31
2300r/min
Soll
0.87v
Soll-cor
0.00mv
0.00mv
Frequency
60Hz
Duty
100%Q_characteristics
18 1900r/min 3.73v 60Hz 100%Cor-Q_ADJ
Confirm no nozzle injection.
Select
Comment
Specifiedpartno.
Pump part no.
Pump serial no.
GE serial no.
Engine model
Rotation
Mode
Pump type
Pump cylinders
ECU
44-6613
44-3062
0880052496
50620-088-52056
VRZ_4M41
Right
Adjustment
VRZ (12V)
4 cylinders
MELCO
Pump information
Step information
Menu Part number input
05/04/03 13:35:08
0.0
0.0
T
Ua-ist V
mm /st3
3
0.0DQ
Q mm /st
Service tools for pump adjustment Adjustment display
Next
Step status
Status I tem Unit Specification ToleranceMeasured / input value
0N r/min
deg C
After values are input, push Next button.Sequence
Present stepNo. S tep name N
07
07 / 31
100r/min
Soll
2.41v
Soll-cor
0.00mv
0.00mv
Frequency
60Hz
Duty
100%Timer_TA
08 50r/min 2.41v 60Hz 100%Timer_TA
100r/min
Select
Comment
Specifiedpartno.
Pump part no.
Pump serial no.
GE serial no.
Engine model
Rotation
Mode
Pump type
Pump cylinders
ECU
44-6613
44-3062
0880052496
50620-088-52056
VRZ_4M41
Right
Adjustment
VRZ (12V)
4 cylinders
MELCO
Pump information
Step information
Menu Part number input
05/04/03 13:20:52
0.0
0.000
T
Ua-ist V
VVTPS
TA mm
Pt MPa
Service tools for pump adjustment Adjustment display
Confirm 50 revolutions (Step 08/31) ~ 1,900
revolutions (Step 16/31) using the sameprocedure used for 100 revolutions (Step 7/31)above.AdviceRepeat Step 06/31 if the timer stroke is notas specified.
[11] Non-injection confirmation(1) Confirm that the sequence is 17/31.(2) Run the inject